Maintenance manager Reliability engineer

DAVID E. STALEY II

**** *. ****** **** **********, MI 48182 419-***-**** ******@****.***

ENGINEERING MANAGER

Mechanical engineering manager with extensive experience in a chemical manufacturing setting, including 11 years of maintenance department management. A strong background of applying six sigma principles to the development and implementation of process and equipment reliability initiatives.

Lean Manufacturing and 6 Sigma principles application

Disciplined Continuous Improvement Implementation

Maintenance Department Leader

Team and Personnel Development

Capital Project Improvement / Manager

Process Safety Management

Refrigeration Systems Maintenance

Hydraulic Systems Maintenance

Maintenance Systems (SAP CMMS Oracle JD Edwards)

Improved Spare Parts Inventory Management

Preventative/Predictive Maintenance

Process Reliability

Process Improvement Analysis

Manufacturing Equipment Reliability

Steam Systems

Electrical Systems / Control Systems

Mechanical Integrity Safety Program

PSM Compliance

Continuous Improvement

PROFESSIONAL EXPERIENCE

GENERAL DYNAMICS LAND SYSTEMS 11/2017 – Present

Engineering Specialist, Lima Ohio

Involved with the day to day plant engineering and working with the facility trade union staff:

Increased the effectiveness and uptime of antiquated equipment through the use of continuous improvement methodologies.

Ensures the high standards of safety are met and maintained at the facility.

Capital Manager for all General Dynamics sponsored projects.

Applied discipline problem solving techniques to underperforming processes, increasing their effectiveness.

Managed and oversaw project budgets.

Coordinated capital spending for entire facility.

Integral part of impending production monitoring systems to aid in improving overall facility OEE.

Manage maintenance department activities to ensure EHS compliance in all areas (proper work techniques, training and tools/equipment).

Started a PSM compliant Mechanical Integrity program.

Coordinates maintenance activities through teamwork with departmental supervisors to insure the total manufacturing objectives are accomplished in a timely and cost effective manner.

Assist in coordinating departmental day to day plant operations, upcoming outages and

Started and monitored Predictive maintenance programs leading to overall uptime improvements.

ARCLIN PERFORMANCE APPLIED 08/2014 – 08/2016

Plant Engineer, Toledo Ohio

Directly supervise plant maintenance personnel and intern(s):

Implemented Lean manufacturing principles throughout functional group. Supported other groups in those initiatives.

Ensures the high standards of safety are met and maintained at the facility.

Manage capital projects in excess of $1 Million annually

Significantly increased plant uptime (20%) while assisting to increase throughput to 100% capacity.

Create and managed Maintenance Facility Maintenance Budget and contractor spending.

Manage maintenance department activities to comply with all city, state & federal regulations, corporate guidelines, PSM and Responsible Care.

Manage maintenance department activities to ensure EHS compliance in all areas (proper work techniques, training, tools/equipment).

Maintain a PSM compliant Mechanical Integrity program.

Coordinates maintenance activities through teamwork with departmental supervisors to insure the total manufacturing objectives are accomplished in a timely and cost effective manner.

Assist in coordinating departmental day to day plant operations, upcoming outages and emergencies related to facility maintenance.

Direct 4 Maintenance employees Engineering Interns and contractors.

Upgraded lubrication plan and procedures.

Manage Maintenance projects such as pressure vessel repair.

CHEMTURA BIOLABS January 2014– August 2014

Maintenance Manager Reliability Leader, Adrian, Michigan

Directly supervise a 12 person team of maintenance individuals and direct their activities to best service the needs of the entire facility. Duties include:

Ensures the high standards of safety are met and maintained at the facility.

Manage maintenance department activities to comply with all city, state & federal regulations, corporate guidelines, PSM and Responsible Care.

Manage maintenance department activities to ensure EHS compliance in all areas (proper work techniques, training, tools/equipment).

Maintain a PSM compliant Mechanical Integrity program.

Coordinates maintenance activities through teamwork with departmental supervisors to insure the total manufacturing objectives are accomplished in a timely and cost effective manner.

Assist in coordinating departmental day to day plant operations, upcoming outages and emergencies related to facility maintenance.

Direct 10 Maintenance employees MRO Parts Clerk and contractors.

Directly impacted production with a 5% uptime increase in the first quarter through proper maintenance planning and procedures.

Upgraded lubrication plan and procedures.

Develop and implement reliability management practices.

Responsible for preventive maintenance program to maintain production machinery and equipment in proper working condition.

Implemented new predictive maintenance procedures and measuring techniques

Respond to production requests for improvements

Maintain SAP Maintenance Work Order Database.

Implement Inventory system

Maintain Predictive Maintenance programs on all equipment.

Purchase all Maintenance materials through SAP.

Entry of new PM procedures into SAP.

Build equipment maintenance tracking system.

Planned all shut down maintenance work.

Organized shutdown schedules

Request bids on equipment and select suppliers.

BRUSH WELLMAN ENGINEERED MATERIALS 2009 – 2014

Reliability Engineer/Head of Maintenance Pebbles Plant, Elmore, Ohio

Directly involved with all activities of building a new facility. This includes set-up of all predictive and preventative maintenance activities. Supervise all maintenance personnel and activities in the new facility.

Direct 12 Maintenance employees and contractors.

Manage Maintenance projects such as pressure vessel repair.

Respond to production requests for improvements

Maintain SAP Maintenance Work Order Database.

Developed Critical Spare Parts Listing.

Build Spare parts tracking and re-supply system.

Maintain Predictive Maintenance programs on all equipment.

Purchase all Maintenance materials through SAP

Entry of all equipment in SAP.

Build equipment maintenance tracking system.

Develop all equipment naming and numbering system.

Maintain government Equipment Inventory List.

Trained in Emerson Delta V control system.

Qualify vendors when applicable.

Request bids on equipment and select suppliers.

GUARDIAN INDUSTRIES 2004 – 2009

Maintenance and Facilities Manager, Millbury, Ohio

Directs and supports 12 maintenance team members in reliability centered maintenance activities, 5S initiatives, preventative maintenance operations and continuous improvement activities.

Ensured preventative and predictive maintenance performance improved and remains effective.

Effectively decreased total plant equipment downtime by four percent through strategic planning with other plant operational areas and the use of CMMS.

One of the Primary participants in TS16949 certification verification audits.

Directs all Facilities improvements and repairs, to include the use of outside vendors when required.

Solicit and negotiate contract bids for maintenance on various plant systems.

Implemented Lean manufacturing principles throughout functional group. Supported other groups in those initiatives.

Trained and appointed as back-up Environmental Manager

Maintained and upgraded fire suppression and prevention system.

Created and implemented various safety improvements throughout plant from personnel observations and employee suggestions.

Maintains all grounds and property through planned use of Landscape contractors.

Process Engineer, Millbury, Ohio

Responsible for day-to-day operations and continuous improvement engineering activities associated with tempering furnace and screen print room operations

Led throughput and quality improvements in OEM tempering and screen print operations.

Decreased unplanned downtime in areas of responsibility by upwards of 80%.

Eliminated the existence of various systemic quality defects leading to verifiable yield increases.

Created and implemented many safety improvements throughout production facility.

Decreased set-up and changeover time for operations through Cross Functional teams.

Provided data and statistical justification for capital expenditures and improvements.

Decreased water usage required by production operations by 50%.

Eliminated Furnace production failures through Poke Yoke maintenance procedures.

Implemented and maintained 5S procedures and standards in areas of responsibility.

Participated in Daimler-Chrysler layered audit program.

Trained production personnel in proper furnace operations and safety procedures.

Implemented safety improvements throughout plant where none existed prior.

PILKINGTON NA 1997 – 2004

Process Improver, Rossford, Ohio

Responsible for day-to-day operations and continuous improvement activities associated with the wareroom operations and performance

Managed all cold end equipment modifications for cycle time reliability and improvement.

Led greenbelt team that reduces glass-cutting defects by 66%.

Guided future improvements and capital expenditures through statistical analysis of key process indicators.

Implemented equipment improvements to reduce manpower in the packaging operations by 33%.

Provided key process ownership and technical support for primary glass packing equipment.

Participated on team that reduced shipping costs and transportation damage by 25%.

Supported ongoing operations through technical support and troubleshooting techniques.

Visited customer sites to address customer quality concerns.

Advanced Tooling Engineer, Northwood, Ohio

Responsible for leading engineering teams in developing glass forming tooling for O.E.M. producers of automotive glass and implementing Pro Engineer design software.

GLASSTECH INC., Perrysburg, Ohio 1995 – 1997

Design Engineer

DAIMLER-CHRYSLER, Detroit, Michigan 1994 – 1995

Production Supervisor – Glass Fabrication

GLASSTECH INC., Perrysburg, Ohio 1992 – 1994

Technical Service Engineer

EDUCATION

Masters of Business Administration, Operations management, Heidelberg College, Maumee, Ohio

Bachelors of Science, Mechanical Engineering, University of Toledo, Toledo, Ohio.

PROFESSIONAL DEVELOPMENT

SAP Work Order Entry

6 Sigma Greenbelt Trained

Radiation Safety Officer Trained

4 completed Greenbelt projects creating substantial yield improvements, cost savings and cycle time reductions.

Trained in SAP Maintenance Modules and other areas of SAP.

Emerson Delta V Programmer trained.

Trained in Teamwork Engineering management software.

Proficient in use of windows software, including Microsoft Project.

Excellent use of Minitab and Wisdom DOE statistical analysis software.

DuPont STOP for Safety and STOP for ergonomics trained.

Daimler Chrysler Statistical Process Control training program.

Global dimensioning and tolerance trained.

Engineer In Training (EIT) exam qualification for professional engineer certification.

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